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A Snapshot of CTI
• Years in business: 32 • History as a supplier of PLC products to Rockwell, Siemens®,
Omron • Main business: 2500 Series® Programmable Controller System:
a 100% compatible replacement for Simatic® 505 • Global presence: offices in 22 countries, 125 employees in sales
and support (including affiliates) • Over 110,000 systems installed worldwide (CTI + Siemens®) • CTI has installed over 120,000 product units worldwide
– Over 19,000 ethernet connections – Over 45,000 serial connections – Over 1.3 million points of analog and digital I/O – Over 3,300 new 2500-Cx00 processors
CTI: A Brief History Three Phases of Company Development
1980 Founded as a spin-off from Computer Concepts Corporation - from the dairy and meat packing process control industry
1983 First industrial products for TI and Allen Bradley
1985 1771-DB Basic Module (Allen-Bradley)
1990 Isolated analog and discrete modules for TI 500 I/O
1991 First TI505 I/O products
1995 2572 Ethernet Module
1997 Siemens® private labeled analog, discrete, and communications modules
2000 SuperSavers I/O Modules
2001 Siemens® announces exit of 505® business
2002 2572-A Fast Ethernet Module
2004 I/O Bases and Profibus RBC
2005 RS485 RBC
2006 Series 500 I/O Adapters
2007 2500 Series® Processors
2008 Worldwide User Conference – Las Vegas USA
2009 CPU performance improvements & new instructions
2011 2500 Series® HMI
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CTI Corporate Headquarters
• Corporate Offices • Product Development • Manufacturing • Sales & Marketing • Factory Hotline • Product Training Knoxville Tennessee
5
Factory Overview – Knoxville TN, USA
• Full industrial surface mount process – solder screen, component placement, solder reflow, automatic test, 100%
industrial burn-in
• RoHS capable process (lead, mercury, cadmium, hexavalent chromium) – Special solders and solding process
– Special coatings
– Special paints
• Products Approvals CE, UL, UL-Canada, Class 1 Div 2
• Quarterly audits and certification by UL
.
solder screen component placement solder reflow automatic test 100% industrial burn-in
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Global Distribution & Support Locations
CANADA
MEXICO
CENTRAL AMERICA
SOUTH AMERICA
CARIBBEAN
EUROPE
AFRICA
ASIA-PACIFIC
AUSTRALIA
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What is the 2500 Series® System?
• New PLC system based on Simatic® 505
• New design based on current technology
• Compatible with your existing Simatic® 505 installations – Interchangeable software
• Same programs and programming tools as your Simatic® 505 systems
– Interchangeable hardware • Simatic® 505 modules can be used in 2500 Series® Systems
• 2500 Series® modules can be used in Simatic® 505 Systems
• I/O modules are direct replacements with no wiring changes
– Simatic® 505 and Series 500 remote I/O networks are supported
8
Project Highlights - USA
Spencer Press
Printing press upgrade of 565 CPU and coaxial I/O to 2500-C300 with new RIO system
Medical Device Manufacturer
Upgrade 555 to 2500-C200 and iFIX SCADA
Textile Manufacturer
Upgrade 545 and TIway to 2500-C200 and Ethernet-based SCADA
Natural Gas Pipeline
Engine control, turbine control, gas & flame detection, overall station control at multiple compressor stations on natural gas pipeline
9
Project Highlights - Europe
Campina (dairy)
Upgrade of 555 CPUs to 2500-C400 using APT®
Air Liquide
New installation with 2500-C100 and CTI I/O
Powerpack (plastics)
Upgrade PM550 to 2500-C200 and CTI I/O with no program changes
Jensen A/S (plating)
Upgrade 555 to 2500-C400 and APT® - achieves 50% more throughput
10
Project Highlights - Asia
Tajco (laser cutting)
Upgrade of S7-300 to 2500-C400 for increased throughput
Chang Chun (chemical)
(1) Upgrade of 545/555 to 2500-C400 and SCADA
(2) New installation with 2500-C400 and 2300 points of I/O
NCFC (cellulose)
Upgrade five 565 to 2500-C300 and eight new I/O bases, new programming software
CJ Biotech (fermentation)
Upgrade 545’s to 2500-C400, new I/O bases, new iFIX SCADA
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Project Highlights - Asia
Plating Plant (auto)
Replace Siemens D7-317 with 2500-C400 and APT®
Semiconductor Plant
Upgrade nine 545 processors to 2500-C200 with no changes in program or SCADA, and only 12 hours downtime
QLD Blow Molders
Upgrade 5TI processors to 2500-C200 with no program changes and only 4 hours downtime
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2500 Series® System Worldwide Support
• Global support organization – USA support (Knoxville, TN) – South America support
• Buenos Aires (Argentina & Brazil) • Santiago, Chile
– European support • Nice, France • Copenhagen, Denmark • Amsterdam, Netherlands • Dublin, Ireland • United Kingdom • Belgium • Germany
– Africa support (Johannesburg, SA) – Asia-Pacific support
• Brisbane, Melbourne, Perth Australia • Taipei, Tainan Taiwan • Shanghai, China • Seoul, Korea • Singapore • Malaysia
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2500 Series® System Components
I/O Base
(4 products)
Power Supply
(4 products)
CPU (4 products)
RBC (2 products)
Vibration
monitoring
Digital I/O
(21 products)
Temperature Input
(6 products)
Analog I/O
(6 products)
Ethernet
(3 products)
Communications
(3 products)
Special I/O
(4 products)
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2500 Series® Processors
2500-C100 2500-C200 2500-C300 2500-C400
Memory 128K 256K 512K 3072K
Digital I/O 1024 2048 8192 8192
Analog I/O 1024 1024 8192 8192
Loops / Alarms 16 / 32 64 / 128 512 / 512 512 / 512
SFP / SFS 64 / 64 1023 / 1023 1023 / 1023 1023 / 1023
Ethernet Yes Yes Yes Yes
Remote I/O No Yes Yes Yes
Profibus No Yes Yes Yes
SD card Yes Yes Yes Yes
USB Yes Yes Yes Yes
Replaces 545-1103*
545-1105*
545-1101
545-1102
545-1104
545-1106
555-1101
555-1103
555-1105
555-1102
555-1104
555-1106
* If Profibus-DP annex card is installed, a 2500-C200 must be used
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Bases
2500P-R4 2500P-R08 2500-R11-A 2500P-R16-A
I/O Slots 4 8 11 16
Compatible with
505-6504 505-6508 505-6511 505-6516
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Power Supplies
2512, 2512-A 2515-A 2513
Output 75W 100W 75W
Input 90-264 VAC 20-30 VDC
compatible with 505-6660
505-6660A/B*
505-6660
505-6660A/B**
505-6663-A
(**) 2515-A also supports redundancy when installed in 2500-R11-A base.
(*) 2512-A is required if redundancy mode is needed. Module needs to be installed in redundant 2500-R11-A base.
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Remote Base Controllers
2500-RBC 2500-RIO-A
Interface Profibus-DP Remote I/O
Compatible with 505-6870 505-6851
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Digital Input Modules
2588-8 2589-A / 2589-B
Channels 8 32 (or 16 or 8)
Login 8 input 32 input (or 16 input)
Isolation in Groups of 2
32pt login: 4 or 8 (selectable)
(16pt login: 4)
(8pt login: 2)
Voltage rating 11V to 250V AC or DC
(selectable by group)
Compatible with
505-4008-A,
505-4108(*),
505-4208-A,
505-4308,
505-4408-A
505-4008-A, 4016-A, 4032-A,
505-4108(*), 4116(*), 4132(*),
505-4208-A, 4216-A, 4232-A,
505-4308, 4316-A, 4332,
505-4408-A, 4416-A, 4432-A
(*) Compatible if used in 12 VDC application or above.
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DC Output Modules
2596-8 2596 2597
Channels 8 16 (or 8) 32 (or 16 or 8)
Type Sourcing
Isolation in Groups of 2 16pt login: 4
8pt login: 2
32pt login: 4 or 8 (selectable)
16pt login: 4
8pt login: 2
Voltage rating 11VDC to 125VDC
Current rating 2A per channel 2A per channel, 32A per module
compatible with 505-4508
505-4708
505-4516
505-4716
505-4532
505-4732
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AC Output Modules
2598-8 2598 2599
Channels 8 16 (or 8) 32 (or 16 or 8)
Isolation in Groups of 2 16pt login: 4
8pt login: 2
32pt login: 4 or 8 (selectable)
16pt login: 4
8pt login: 2
Voltage rating 11VAC to 240VAC
Current rating 2A per channel 2A per channel, 32A per module
Compatible with 505-4608
505-4808
505-4616
505-4816
505-4632
505-4832
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Relay Output Modules
2534 2532 2531
Channels 8 16 32
Type Form-C Form-A Form-A
Voltage rating 12VDC to 30VDC, 12VAC to 250V AC
Current rating 4A per channel, 32A per module
4A per channel, 8A per group, 32A per module
compatible with 505-4908 505-4916-A 505-4932-A
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Analog Modules
2558 2562 2501
Channels 8 input 8 output 8in / 4out
Ranges 0-5V, 0-10V, 0-20mA, 4-20mA, unipolar and bipolar,
selectable by channel
Resolution 16 bits 12 bits 16 bits input, 12
bits output
Update time 4msec 7msec
Compatible with 505-6108-A
505-6108-B
505-6208-A
505-6208-B
505-7012
505-7016
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Temperature Modules
2559-TC 2559-RTD
Channels 8 thermocouple input
8 RTD input
Ranges J, K, T, E, R, S, N, and
mV
100Ω, 200Ω, 500Ω platinum, 120Ω
nickel, 10Ω copper
Update time 9msec
compatible with 505-7028-A 505-7038
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Counter Module
2502
Channels 2
Counters
(per channel) One 16-bit
Count Inputs
(per channel) 2
Control Inputs
(per channel) 2
Outputs
(per channel) 2
compatible with 505-7002
2500P-ECC1 Ethernet Communications Coprocessor
• Advanced Ethernet communications solution for CTI 2500-Cxxx Processors
• CAMP (CTI ASCII Messaging Protocol) – Server and Client (includes multicast)
– Allows communication with 2572, 2572-A, and 2500 Series® Processors, HMI which support CAMP (or OPC)
• Open Modbus (Ethernet) – Modbus Server
– Modbus Client
• Network Data Exchange – Shares with other 2500P-ECC1 and CTI HMI panels
– Publish/ Subscribe Model
– Publish based on change in value
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• High performance connection from PLC to HMIs
• Client/Server connection to legacy PLCs with 2572/2572-A
• Flexible Network Data Exchange to multiple PLCs with 2500P-ECC1s
• Connection to Open Modbus devices using client or server
• All with no programming
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2500P-ECC1 Ethernet Communications Coprocessor
2572-A Fast Ethernet Module
• Direct 100Mbit connection using RJ45
• More throughput ( 2X – 3X) than 2572
• Enhanced PLC access
• New additional protocol support (Modbus TCP and Ethernet/IP
• Web server access for diagnostics and configuration
• Enhanced event logging for troubleshooting
• DHCP with module ID
• Flash upgradeable
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And many other solutions . . .
• Vibration monitoring • Analog and digital I/O with individual isolation between
channels – 11 products • TTL inputs & outputs • 16-point analog and temperature input modules • Specialized counter modules • Ethernet (4 solutions), Profibus-DP, Modbus, DeviceNet™ • Processor redundancy
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Product Spotlight Vibration Monitoring
2505 Vibration Sensor Interface Module
• 4 transducer channels + tachometer channel
• Each transducer channel supports proximity, velocity, or accelerometer transducers
• Reports RMS and peak vibration to PLC, along with speed
• Monitors and reports alarm conditions
31
Product Spotlight Upgrading TI Series 500 Systems
• 2500-IADP I/O Adapter
• 2500-PADP Power Supply Adapter
• 2500-RADP RBC Adapter
• 2500-ADP1 Analog Wiring Adapter
• 2500-ADP2 Discrete Wiring Adapter
• 2500-R4500 Adapter Base
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Product Spotlight Redundancy & Backup Solutions – Remote Bases
• Redundant RBC
• Redundant power
• Redundant power & redundant RBCs
34
Product Spotlight CPU Redundancy
2541 Redundant Processor Manager • Allow use of two 2500 Series® CPUs in a
redundant backup configuration • I/O is connected to the control PLC using
relay contacts • Both PLCs see the inputs all the time • 2541 monitors both PLCs and switches the
I/O to the backup PLC in case of fault • Critical data is written to the backup PLC • No change in outputs when switching
from primary to backup
35
Product Spotlight Redundancy & Backup Solutions – Processors
• Redundant power & redundant CPUs using Redundant Processor Manager
To remote bases
37
• Conformal coating protects against moisture, fungus, dust and corrosion caused by extreme environments
• Should be used especially if the environment has levels of H2S, SO2, CL2, or NO2 in concentrations above the following levels: – H2S >10 ppb
– SO2 >1000 ppb
– CL2 >2 ppb
– NO2 >125 ppb
– ppb = parts per billlion
Product Spotlight Conformal Coating
38
2500 Series® Programming Tools
• PLC Workshop Suite™ – Primary programming platform
– Runs under Windows
– Includes integrated Profibus configurator
– Ongoing development and enhancement
– Current version 4.60 includes new instructions
• APT® – Enriched programming
platform for process control
• TISOFT™ – DOS-based legacy platform